Microwave heating construct with elevatable bottom

ABSTRACT

A microwave heating construct includes a movable portion defined at least partially by lines of disruption extending between adjacent edges of the bottom panel. The movable portion is adapted to be moved towards the interior space for maintaining a food item in an elevated position within the construct. A susceptor or other microwave energy interactive element may be joined to the movable portion to enhance heating, browning, and/or crisping of the food item.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/188,925, filed Aug. 14, 2008, which is incorporated by referenceherein in its entirety.

TECHNICAL FIELD

This disclosure relates generally to various blanks, constructs,systems, and methods for containing, heating, browning, and/or crispinga food item in a microwave oven.

BACKGROUND

Microwave ovens provide a convenient means for heating a variety of fooditems, including dough-based products such as pizzas and pies. However,microwave ovens tend to cook such items unevenly and are unable toachieve the desired balance of thorough heating and a browned, crispcrust. Many commercially available packages attempt to brown and/orcrisp the bottom surface of the food item without addressing the need tobrown and/or crisp the crust or dough on the top or edges of the fooditem. Thus, there is a need for a system that provides the desireddegree of heating, browning, and/or crisping of both the bottom and topsurfaces of the crust or dough of a food item.

SUMMARY

This disclosure relates generally to various cartons, containers, orpackages (generally referred to as “constructs”), various blanks forforming such constructs, methods of making such constructs, and methodsof using such constructs to heat, brown, and/or crisp a food item in amicrowave oven. The constructs also may be used to contain the food itemprior to heating. In some examples, the construct may be used with oneor more additional components to form a microwave energy interactivesystem.

The various constructs generally include one or more reconfigurablepanels or portions for elevating the food item from the floor of themicrowave oven to enhance the heating, browning, and/or crisping of thefood item. For example, the construct may include a bottom panel thatincludes a movable portion that may be moved from a first positionsubstantially coplanar with the remainder of the bottom panel to asecond position out of the plane of the remainder of the bottom panel.In the second position, the movable portion may serve as a platform formaintaining the food item in an elevated condition during heating. Thetransformation from a storage receptacle or container to a heating,browning, and/or crisping construct may comprise separating one or moreportions of the container, folding one or more portions of the containeror portions removed therefrom, inverting one or more portions of thecontainer or portions removed therefrom, any other transformation, orany combination of transformations.

The constructs may include one or more additional features to enhancethe heating, browning, and/or crisping of the food item, for example,microwave energy interactive elements, apertures, vents, insulatingelements, or any combination thereof.

Other features, aspects, and embodiments of the invention will beapparent from the following description and accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The description refers to the accompanying drawings in which likereference characters refer to like parts throughout the several views,and in which:

FIG. 1A is a schematic top plan view of one side of an exemplary blankthat may be used to form a construct;

FIG. 1B is a schematic perspective view of a partially erected constructformed from the exemplary blank of FIG. 1A;

FIG. 1C is a schematic perspective view of a fully erected constructformed from the exemplary blank of FIG. 1A;

FIG. 1D is a schematic perspective view of the construct of FIG. 1C, inan inverted, partially open configuration;

FIG. 1E is a schematic perspective view of the construct of FIG. 1D,with the movable panel moved toward the interior of the construct;

FIG. 1F is a schematic perspective view of the construct of FIG. 1E, inan upright configuration with an open end;

FIG. 1G is a schematic perspective view of the construct of FIG. 1F,with the removable portion removed from the top panel;

FIG. 2 is a schematic top plan view of an exemplary microwave energyinteractive tray or card that may be used to heat, brown, and/or crisp afood item; and

FIG. 3 is a schematic perspective view of an exemplary conventionalmicrowave energy interactive ring that may be used to heat, brown,and/or crisp a food item.

DESCRIPTION

The present invention may be described further by referring to thefigures. For purposes of simplicity, like numerals may be used todescribe like features. It will be understood that where a plurality ofsimilar features are depicted, not all of such features necessarily arelabeled on each figure. It also will be understood that variouscomponents used to form the blanks and constructs of the presentinvention may be interchanged. Thus, while only certain combinations areillustrated herein, numerous other combinations and configurations arecontemplated hereby.

FIG. 1A depicts a first side of an exemplary blank 100 that may be usedto form a construct 192 or apparatus (e.g., a package or carton) forheating, browning, and/or crisping a food item in a microwave oven(discussed in connection with FIGS. 1C-1G). The blank 100 generallyincludes a plurality of adjoined panels, each of which has a firstdimension, for example, a length, extending in a first direction, forexample, a longitudinal direction, D1, and a second dimension, forexample, a width, extending in a second direction, for example, atransverse direction, D2. It will be understood that such designationsare made only for convenience and do not necessarily refer to or limitthe manner in which the blank is manufactured or erected into aconstruct. The side of the blank 100 shown in FIG. 1A may form theinterior side 190 of the construct 192 (FIG. 1C), as will be evidentfrom the remaining discussion.

As shown in FIG. 1A, the blank 100 includes a first major panel (orfirst main panel) 102 and a second major panel (or second main panel)104 that may respectively serve as a bottom panel 102 and top panel 104for the construct 192 (FIGS. 1C-1G) to be formed from the blank 100. Afirst side panel 106 is joined to the panel 102 along a longitudinalline of disruption, for example, fold line 108. A panel or flap 110(e.g., a gluing panel or flap) is joined to panel 102 along alongitudinal line of disruption, for example, fold line 112 opposite andsubstantially parallel to longitudinal fold line 108. A pair of opposedend panels 114, 116 is joined to panel 102 along respective transverselines of disruption, for example, fold lines 118, 120, which may besubstantially parallel to one another. Fold lines 108, 112 may besubstantially perpendicular to fold lines 118, 120 such that panel 102has a substantially square shape, with fold lines 108, 112, 118, 120extending substantially along and/or defining the peripheral edges ofpanel 102. However, other configurations of fold lines and shapes arecontemplated hereby.

A plurality of oblique lines of disruption 122, 124, 126, 128 extendsubstantially between each pair of adjacent edges of panel 102 (i.e.,substantially along fold lines 108, 112, 118, 120). In this example, thelines of disruption are shown as tear lines. However, it is contemplatedthat cuts or slits may be used. Tear line 122 extends substantiallybetween fold lines 108, 118, tear line 124 extends substantially betweenfold lines 112, 118, tear line 126 extends substantially between foldlines 108, 120, and tear line 128 extends substantially between foldlines 112, 120. The oblique lines of disruption 122, 124, 126, 128 andthe portions 108′, 112′, 118′, 120′ of the fold lines 108, 112, 118, 120that lie between the endpoints of the oblique lines of disruption 122,124, 126, 128 collectively circumscribe or define a movable portion 102′of panel 102 that may serve as a platform for maintaining a food item(not shown) in a raised position relative to the floor or turntable of amicrowave oven, as will be discussed in connection with FIGS. 1F and 1G.

In this example, the oblique tear lines 122, 124, 126, 128 aresubstantially equal in length and their respective ends (i.e.,endpoints) are equidistant from the respectively adjacent corner ofpanel 102, such that the resulting movable portion 102′ has asubstantially symmetrical, substantially octagonal shape. Alternatively,the movable portion 102′ can be thought of as having a substantiallysquare shape with chamfered corners. However, other regular andirregular shapes are contemplated by the disclosure. Further, it is alsocontemplated that non-oblique lines of disruption may be used to formthe movable portion 102′. For example, each oblique fold line may bereplaced with one or more transverse and/or longitudinal fold lines. Theoverall shape of the movable portion 102′ may vary for each embodiment.

As will be evident from the figures, since the movable portion 102′ ofpanel 102 includes some edges that are substantially collinear with theedges of the panel 102 along fold line portions 108′, 112′, 118′, 120′,the remainder of panel 102 (i.e., the portion of panel 102 excluding themovable portion 102′) includes four corner portions that aresubstantially isolated or discrete from one another. However, it iscontemplated that the oblique tear lines 122, 124, 126, 128 and the foldlines connecting them (in this example, fold line portions 108′, 112′,118′, 120′) may be distanced from each peripheral edge of panel 102,such that the movable portion 102′ may be circumscribed by the remainderof the panel 102 along each peripheral edge of the panel 102.

Still viewing FIG. 1A, panels 106, 110 each include a respective pair oftransverse lines of lines of disruption (e.g., cuts, slits, or tearlines) 130, 132 extending away from the respective fold line 108, 112substantially from the endpoints of the respective oblique tear lines122, 124, 126, 128 into the respective panel 106, 110. A longitudinalline of disruption (e.g., a fold line or score line) 134, 136 extendssubstantially between the endpoints of each respective pair oftransverse lines of disruption 130, 132. Similarly, panels 114, 116 eachinclude a respective pair of longitudinal lines of lines of disruption(e.g., cuts, slits, or tear lines) 138, 140 extending away from therespective fold line 118, 120 into the respective panel 114, 116. Atransverse line of disruption 142, 144 (e.g., a fold line or score line)extends substantially between the endpoints of each respective pair oflongitudinal lines of disruption 138, 140.

For each panel 106, 110, 114, 116, cuts 130, 132, 138, 140, fold lines134, 136, 142, 144, and fold line portions 108′, 112′, 118′, 120′joining their respective endpoints define a hingeable portion 106′,110′, 114′, 116′ of the respective panel 106, 110, 114, 116. Eachhingeable portion 106′, 110′, 114′, 116′ is foldably joined to themovable portion 102′ of the bottom panel 102 along the respectively foldline portion 108′, 112′, 118′, 120′. In this example, each hingeableportion 106′, 110′, 114′, 116′ is substantially centered along the majorlinear dimension of the respective panel 106, 110, 114, 116, (i.e., thefirst dimension D1 of panels 106, 110 and the second dimension D2 ofpanels 114, 116). Further, in this example, the cuts 130, 132, 138, 140are substantially perpendicular to the respectively adjacent fold lineportion 108′, 112′, 118′, 120′ and to the respectively adjacent foldline 134, 136, 142, 144, such that the resulting hingeable portion 106′,110′, 114′, 116′ is substantially rectangular in shape. However, it iscontemplated that the cuts or other lines of disruption may bepositioned otherwise and/or may be oblique to one other to definedifferently positioned and/or shaped hingeable portions. The hingeableportion 106′, 110′, 114′, 116′ of each panel 106, 110, 114, 116 mayserve as an elevating panel or support panel for the movable portion102′ of the bottom panel 102, as will be described in connection withFIGS. 1F and 1G.

If desired, a microwave energy interactive element 146 (shownschematically with stippling), for example, a susceptor, may overlieand/or may be joined to all or a portion of the bottom panel 102 todefine a microwave energy interactive heating surface for receiving thefood item (i.e., for supporting the food item in a facing, substantiallycontacting relationship). In this example, the susceptor 146 overliessubstantially the entire movable portion 102′ of the bottom panel 102,while the remaining portion or remainder of the bottom panel 102 (inthis example, the corner areas) is microwave energy transparent. Howeverother configurations of the susceptor 146 and other microwave energyinteractive elements may be used, as will be discussed further below.For example, in one embodiment (not shown), the susceptor may overliethe entirety of the bottom panel 102.

Still viewing FIG. 1A, the second major panel (or second main panel) 104includes a removable portion 104′ defined at least partially by a lineof disruption, for example, a tear line 148. If desired, the removableportion 104′ may include a tab 150 defined by a line of disruption, forexample, a cut line or cut 152 (or slit), that may initiate andterminate substantially along tear line 148. In this example, the cut152 is substantially arcuate in shape, such that the tab 150 has asubstantially semi-circular shape. However, it will be understood thatin this and other examples, the tab may have any shape as needed ordesired. For example, the tab may be oval, rectangular, square,diamond-shaped, trapezoidal, polygonal, or any other regular orirregular shape. If desired, the tear line 148 may be interrupted by ascore line 154 that extends substantially between the endpoints of cut152. The score line 154 may assist with activation or use of the tab150.

The top panel 104 is joined to the first side panel 106 along alongitudinal fold line 156. The top panel 104 also is joined to a secondside panel 158 along a longitudinal fold line 160 opposite andsubstantially parallel to longitudinal fold line 156. Panel 158 includesa substantially rectangular cutout 162 generally corresponding to thedimensions and shape of the movable portion 110′ of panel 110. In thismanner, when the blank 100 is formed into a construct 192 (FIG. 1C) andpanel 158 is overlapped with panel 110, panel 158 will not interferewith the operation of the movable portion 110′ of panel 110.

Respective pairs of tuck-in panels 164, 166 are joined respectively toopposite longitudinal ends of panels 106, 158 along respective opposedpairs of transverse fold lines 168, 170.

The blank 100 also includes a pair of end panels 172, 174 joined topanel 104. End panel 172 is joined to panel 104 along a transverse foldline 176. End panel 174 is joined to panel 104 along a transverse lineof disruption, which in this example, is one tear line 178 of a pair oftear lines 178, 180 that collectively define a tear strip 182. In theillustrated embodiment, each tear line 178, 180 comprises a plurality of“zipper” cuts, each of which generally includes a transverse portion andan oblique portion, such that the plurality of cuts collectivelyresemble a zipper. However, other types of tear lines may be used todefine the tear strip 182. It is noted that in this example both endpanels 172, 174 have a first dimension D1 that is less than the firstdimension D1 of the respective end panels 114, 116 to prevent overlapand/or interference with the operation of the respective hingeableportions 114′, 116′ of panels 114, 116 when the blank 100 is formed intoa construct 192 (FIG. 1C). However, other configurations of panels andother types of cartons are encompassed by the disclosure.

If desired, a microwave energy interactive element 184 (shownschematically with stippling), for example, a susceptor, may overlieand/or may be joined to all or a portion of panel 104 to form amicrowave energy interactive cover for the food item. In this example,the susceptor 184 is in the shape of a ring or annulus that encircles orcircumscribes the removable portion 104′. The peripheral margin of panel104, which circumscribes (i.e., extends around) the susceptor 184, istransparent to microwave energy. However other configurations and othermicrowave energy interactive elements may be used. For example, in oneembodiment (not shown), the susceptor 184 may overlie the entirety ofthe panel 104.

To form a construct 192 (FIG. 1C) from the blank 100 according to oneexemplary method, panels 102, 104 may be brought into a superposedarrangement by folding along fold lines 108, 156. Panels 158, 110 may beoverlapped with one another by folding along respective fold lines 160,112 and joined to one another adhesively, mechanically, or using anyother suitable technique to form a somewhat tubular structure 186 havingan interior space 188 or cavity for receiving the food item (not shown),as depicted in FIG. 1B. In this configuration, the microwave energyinteractive elements 146, 184 (hidden from view in FIG. 1B) overlieand/or define at least a portion of an interior surface 190 of thestructure 186.

The tuck-in panels 164, 166 may be folded toward the interior 186 of thetubular structure 186 along respective fold lines 168 (FIG. 1A), 170.End panels 114 (FIG. 1A), 116 may be folded inwardly toward the tuck-inpanels 164, 166 by folding along respective fold lines 118 (FIG. 1A),120. Likewise, end panels 172, 174 may be folded inwardly along foldlines (i.e. lines of disruption) 176, 178 and adhered respectively toend panels 114, 116 adhesively, mechanically, or using any othersuitable technique to form the construct 192, as shown in FIG. 1C. Inthe fully erected construct 192, panels 102, 104 serve respectively asbottom and top panels 102, 104 of the construct 192, while panels 106,110, 114, 116, 158, 172, 174 define side or end panels (or walls) (onlyvisible panels labeled in FIG. 1C) of the construct 192.

The food item (not shown) may be inserted into the construct 192 at anysuitable time. Alternatively, the construct 192 may be formed “around”the food item to be contained in the construct.

To use the construct 192 according to one exemplary method, the tearstrip 182 may be activated (i.e., torn away from the remainder of theconstruct 192) to access the food item within the interior 188 (FIG. 1B)of the construct 192. The construct 192 then may be inverted as shown inFIG. 1D, and the movable portion 102′ may be urged out of the plane ofthe remainder of the bottom panel 102 towards the interior space 188 bytearing along the lines of disruption 122, 124, 126, 128, folding alongfold line portions 108′, 112′, 118′, 120′, and pivoting the hingeableportions 106′, 110′, 114′, 116′ along fold lines 134, 136, 142, 144, asshown in FIG. 1E. In this configuration, the remainder of the bottompanel 102 substantially lies in a first plane and the movable portion102′ lies in a second plane closer to the interior space 188. Thedistance between the first and second planes defines a plurality ofventing gaps 194 adjacent to the remainder of the bottom panel (i.e.,the corner portions) 102, as shown in FIG. 1E.

The construct 192 then may be inverted again to bring the construct 192into an upright configuration, as shown schematically in FIG. 1F. Inthis configuration, the movable portion 102′ of the bottom panel 102 issomewhat elevated, such that the movable portion 102′ of the bottompanel 102 may serve as a platform 102′ for receiving the food item. Theplatform 102′ is maintained in an elevated position by hingeableportions 106′, 110′, 114′, 116′, such that the hingeable portions 106′,110′, 114′, 116′ may be referred to as “elevating portions” or“elevating panels”. A void (hidden from view) is formed beneath theplatform 102′.

The removable portion 104′ (FIG. 1F) of the top panel 104 may removed bygrasping the tab 150 (or otherwise) and tearing along tear line 148,thereby forming an opening 196 in the top panel 104, as shown in FIG.1G. The opening 196 may be configured (e.g., positioned and/ordimensioned) to overlie an area of the food item that is not intended tobe browned and/or crisped, while all or a portion of the remainder ofthe top panel 104 (i.e., all of the top panel 104 except the removableportion 104′) may be provided with a microwave energy interactiveelement, for example, susceptor 184 (shown with dashed lines in FIG.1G), to overlie an area of the food item that is desirably brownedand/or crisped. For example, where the food item is a pizza, the opening196 may be dimensioned to overlie the toppings, while the susceptor 184(FIG. 1A) may be dimensioned to overlie the top of the crust of thepizza. The opening 196 also may serve as an access opening or windowthrough which the food item may be viewed and/or adjusted if needed(e.g., to rearrange the toppings on a pizza).

The food item may be reinserted into the interior space 188 at anysuitable time, for example, before or after the removable portion 104′is removed. The food item within the construct 192 then may be heated ina microwave oven according to the package directions. After sufficientexposure to microwave energy, the microwave energy interactive elements184, 146 on the respective interior side 190 of the bottom and toppanels 102, 104 convert at least a portion of the impinging microwaveenergy into thermal energy, which then can be transferred to the surfaceof the food item to enhance browning and/or crisping. Further, thevarious elevating panels 106′, 110′, 114′, 116′ cooperate to support theplatform 102′ and maintain the food item in a raised position in themicrowave oven. While not wishing to be bound by theory, it is believedthat the air in the void between the platform 102′ and the floor of themicrowave oven provides an insulating effect that reduces the loss ofheat from the susceptor 146 to the microwave oven. Thus, more of theheat generated by the susceptor is available for transfer to the fooditem. Additionally, the venting gaps 194 may allow any steam generatedduring heating to be carried away from the food item, thereby furtherbrowning and/or crisping the food item. The opening 196 in the top panel104 and the open end of the construct 192 may provide additionalventing. After heating, the food item can be removed from the construct192 and served as desired.

It will be appreciated that the elevating panels 106′, 110′, 114′, 116′and lines of disruption 122, 124, 126, 128 between the elevating panels106′, 110′, 114′, 116′ can be configured to provide the desired degreeof insulation and/or venting needed for a particular food item. Forexample, where less venting and/or insulation is needed, the elevatingpanels and lines of disruption can be configured to provide a smallervoid or airspace beneath the construct and/or smaller venting gaps.Conversely, where additional insulation and/or venting is needed, theelevating panels and lines of disruption can be configured to provide alarger void or airspace beneath the construct and/or smaller ventinggaps.

Numerous variations of the blank 100 and construct 192 of FIGS. 1A-1Gare contemplated by the disclosure. Any of such variations may be usedalone or in combination with one another.

For example, in one variation, the construct 192 may be provided with acard, disk, or tray (generally “tray”) 200 for supporting the food item,as shown in FIG. 2, to form a microwave heating system. In the exampleshown schematically in FIG. 2, the tray 200 includes a first portion 202for receiving the food item and a second portion 204 that serves as ahandle for grasping the tray 200. The first portion 202 is substantiallycircular in shape, for example, for receiving a somewhat circular fooditem, and the handle 204 is somewhat triangular or arrow-shaped.However, differently shaped trays and handles may be used. Further, thehandle may be omitted if desired. The tray 200 may be dimensioned to bereceived in the interior 188 of the construct 192 (seated on the bottompanel 102 or on the elevated portion 102′ of the bottom panel 102), suchthat the food item can remain seated on the tray 200 prior to, during,and/or after heating for conveniently transporting the food item to andfrom the interior space 188. In some instances, the tray 200 also mayserve as a cutting “board” on which the food item may be divided intoportions after heating. In any of such embodiments, the tray may beformed at least partially from a dimensionally-stable base material orsupport, for example, paperboard or plastic. The tray 200 may beprovided as a separate component or may comprise a removable portion ofthe top panel, for example, as with removable portion 104′ of panel 104.

If desired, the tray 200 may include one or more microwave energyinteractive elements that alter the effect of microwave energy on thefood item. In the illustrated example, the tray 200 includes a susceptor206 (shown schematically with stippling) overlying and/or joined to thefirst portion 202 of the tray 200, such that when the tray 200 isinserted into the construct 192, the susceptor 206 on the tray 200 is atleast partially superposed with the susceptor 146 on the bottom panel102. In this manner, additional heat may be generated and transferred tothe food item. In another variation, the susceptor 146 on the bottompanel 102 may be omitted.

The tray 200 also includes a plurality of metal foil segments, some ofwhich are arranged to form a plurality of microwave energy distributingelements 208 that are operative for directing microwave energy towardsthe center of the tray 200, and therefore, towards the center of thefood item seated on the tray 200. The remaining foil segments 210 (i.e.,positioned along the peripheral margin of the tray) serve as microwaveenergy shielding elements for reducing the amount of microwave energythat reaches the peripheral margin of the food item. In this example,the shielding elements 210 are substantially hexagonal in shape, butdifferently shaped shielding elements may be used.

If desired, the second portion 204 of the tray 200 may be substantiallytransparent to microwave energy. As a result, the handle 204 may remainsubstantially cool after exposure to microwave energy so the handle canbe gripped comfortably by a user. Exemplary methods of forming amicrowave energy transparent handle will be discussed below.

In other embodiments, one or more of such elements 206, 208, 210 may beomitted, reconfigured, and/or replaced with other microwave energyinteractive elements. Countless possibilities are contemplated. Further,it will be appreciated that the exemplary tray 200 of FIG. 2 andnumerous others contemplated by the present disclosure may be used innumerous other embodiments and heating applications, with or without theconstruct 192 of FIGS. 1C-1G.

In another exemplary system, the susceptor 184 on the top panel 104 maybe omitted and the construct 192 may be provided with a microwave energyinteractive cover for overlying all or a portion of the food item withinthe interior 188 of the construct 192. In one embodiment illustrated inFIG. 3, the cover comprises a conventional contoured ring 300 configuredto overlie the peripheral margin of the food item. The inner side of thering 300 may include a microwave energy interactive element, forexample, a susceptor 302 (shown schematically with stippling) foroverlying areas of the food item that are intended to be browned and/orcrisped (e.g., the top surface and/or sides of the food item), forexample, the crust of a pizza. The ring 300 includes a substantiallycircular opening 304 for overlying areas of the food item that are notintended to be browned and/or crisped, for example, the toppings of apizza. Where the food item is shipped within the construct, the ring 300also may serve to protect the food item during shipping.

In still another variation, the removable portion 104′ of the top panel104 may be omitted. In such examples, the construct 192 may include awindow through which the food item may be viewed. The viewing window maycomprise a polymer film or any other suitable material. Depending on theparticular heating application, the user may be instructed to remove thepolymer film prior to heating the food item in a microwave oven.

In other variations, the various panels, portions, and other featuresmay independently have any suitable shape, for example, circular, oval,triangular, square, rectangular, pentagonal, hexagonal, heptagonal,octagonal, or any other regular or irregular shape. The shape of thevarious panels and the resulting construct may be determined by theshape of the food product, and it will be understood that differentshapes are contemplated for different food products, for example,sandwiches, pizzas, pastries, doughs, and so forth.

Any of such constructs may be formed from various materials, providedthat the materials are substantially resistant to softening, scorching,combusting, or degrading at typical microwave oven heating temperatures,for example, at from about 250° F. to about 425° F. The materials mayinclude microwave energy interactive materials, for example, those usedto form susceptors and other microwave energy interactive elements, andmicrowave energy transparent or inactive materials, for example, thoseused to form the remainder of the construct.

The microwave energy interactive material may be an electroconductive orsemiconductive material, for example, a metal or a metal alloy providedas a metal foil; a vacuum deposited metal or metal alloy; or a metallicink, an organic ink, an inorganic ink, a metallic paste, an organicpaste, an inorganic paste, or any combination thereof. Examples ofmetals and metal alloys that may be suitable include, but are notlimited to, aluminum, chromium, copper, inconel alloys(nickel-chromium-molybdenum alloy with niobium), iron, magnesium,nickel, stainless steel, tin, titanium, tungsten, and any combination oralloy thereof.

Alternatively, the microwave energy interactive material may comprise ametal oxide, for example, oxides of aluminum, iron, and tin, optionallyused in conjunction with an electrically conductive material. Anothermetal oxide that may be suitable is indium tin oxide (ITO). ITO has amore uniform crystal structure and, therefore, is clear at most coatingthicknesses.

Alternatively still, the microwave energy interactive material maycomprise a suitable electroconductive, semiconductive, or non-conductiveartificial dielectric or ferroelectric. Artificial dielectrics compriseconductive, subdivided material in a polymeric or other suitable matrixor binder, and may include flakes of an electroconductive metal, forexample, aluminum.

The microwave energy interactive material(s) may be used to form one ormore microwave energy interactive elements or features that alter theeffect of microwave energy on the adjacent food item. Each microwaveenergy interactive element comprises one or more microwave energyinteractive materials or segments arranged in a particular configurationto absorb microwave energy, transmit microwave energy, reflect microwaveenergy, or direct microwave energy, as needed or desired for aparticular microwave heating construct and food item. The microwaveenergy interactive element may be configured to promote browning and/orcrisping of a particular area of the food item, shield a particular areaof the food item from microwave energy to prevent scorching oroverheating, or transmit microwave energy towards or away from aparticular area of the food item.

For example, as discussed above, the microwave energy interactiveelement may comprise a susceptor element (e.g., elements 146, 184, 206,302), i.e., a thin layer of microwave energy interactive material(generally less than about 100 angstroms in thickness, for example, fromabout 60 to about 100 angstroms in thickness, and having an opticaldensity of from about 0.15 to about 0.35, for example, about 0.21 toabout 0.28) that tends to absorb at least a portion of impingingmicrowave energy and convert it to thermal energy (i.e., heat).Susceptor elements often are used to promote browning and/or crisping ofthe surface of a food item. However, other microwave energy interactiveelements, such as those described herein, are contemplated by thedisclosure.

Alternatively or additionally, the microwave energy interactive elementmay comprise a foil or high optical density evaporated material having athickness sufficient to reflect a substantial portion of impingingmicrowave energy. Such elements are typically formed from a conductive,reflective metal or metal alloy, for example, aluminum, copper, orstainless steel, in the form of a solid “patch” generally having athickness of from about 0.000285 inches to about 0.05 inches, forexample, from about 0.0003 inches to about 0.03 inches. Other suchelements may have a thickness of from about 0.00035 inches to about0.020 inches, for example, 0.016 inches.

Larger microwave energy reflecting elements may be used where the fooditem is prone to scorching or drying out during heating. Smallermicrowave energy reflecting elements (e.g., elements 210) may be used todiffuse or lessen the intensity of microwave energy. A plurality ofsmaller microwave energy reflecting elements also may be arranged toform a microwave energy directing element (e.g., elements 208) to directmicrowave energy to specific areas of the food item. If desired, thereflective elements of the microwave energy directing element may bearranged a loop having a length that causes microwave energy toresonate, thereby enhancing the distribution effect. Microwave energydistributing elements are described in U.S. Pat. Nos. 6,204,492,6,433,322, 6,552,315, and 6,677,563, each of which is incorporated byreference in its entirety.

If desired, any of the numerous microwave energy interactive elementsdescribed herein or contemplated hereby may be substantially continuous,that is, without substantial breaks or interruptions, or may bediscontinuous, for example, by including one or more breaks or aperturesthat transmit microwave energy therethrough. The breaks or apertures maybe sized and positioned to heat particular areas of the food itemselectively. The breaks or apertures may extend through the entirestructure, or only through one or more layers. The number, shape, size,and positioning of such breaks or apertures may vary for a particularapplication depending on the type of construct being formed, the fooditem to be heated therein or thereon, the desired degree of shielding,browning, and/or crisping, whether direct exposure to microwave energyis needed or desired to attain uniform heating of the food item, theneed for regulating the change in temperature of the food item throughdirect heating, and whether and to what extent there is a need forventing.

It will be understood that the aperture may be a physical aperture orvoid in one or more layers or materials used to form the construct, ormay be a non-physical “aperture”. A non-physical aperture is a microwaveenergy transparent area that allows microwave energy to pass through thestructure without an actual void or hole cut through the structure. Suchareas may be formed by simply not applying a microwave energyinteractive material to the particular area, or by removing microwaveenergy interactive material in the particular area, by mechanicallydeactivating the microwave energy interactive material in the particulararea, or by chemically deactivating the microwave energy interactivematerial in the particular area (such that the microwave energyinteractive material is chemically transformed into a material that issubstantially transparent to microwave energy). While both physical andnon-physical apertures allow the food item to be heated directly by themicrowave energy, a physical aperture also provides a venting functionto allow steam or other vapors to escape from the interior of theconstruct.

The arrangement of microwave energy interactive and microwave energytransparent areas may be selected to provide various levels of heating,as needed or desired for a particular application. For example, wheregreater heating is desired, the total inactive (i.e., microwave energytransparent) area may be increased. In doing so, more microwave energyis transmitted to the food item. Alternatively, by decreasing the totalinactive area, more microwave energy is absorbed by the microwave energyinteractive areas, converted into thermal energy, and transmitted to thesurface of the food item to enhance heating, browning, and/or crisping.

In some instances, it may be beneficial to create one or morediscontinuities or inactive regions to prevent overheating or charringof the construct. Such areas may be formed by forming these areas of theconstruct without a microwave energy interactive material, by removingany microwave energy interactive material that has been applied, or bydeactivating the microwave energy interactive material in these areas,as discussed above.

By way of example, and not limitation, in the tray 200 illustratedschematically in FIG. 2, it may be desirable to have the handle 204remain substantially cool to the touch so that a user may grasp thehandle comfortably. As such, the handle 204 may be designed to bemicrowave energy transparent, for example, by forming the handle 204without a microwave energy interactive material, by removing anymicrowave energy interactive material that has been applied, or bydeactivating the microwave energy interactive material in these areas.

Further still, one or more panels, portions of panels, or portions ofthe construct may be designed to be microwave energy inactive to ensurethat the microwave energy is focused efficiently on the areas to bebrowned and/or crisped, rather than being lost to portions of the fooditem not intended to be browned and/or crisped or to the heatingenvironment. This may be achieved using any suitable technique, such asthose described above.

Any of the various microwave energy interactive elements (e.g., elements146, 162, 206, 208, 210, 302) may be supported on a microwave inactiveor transparent substrate, for example, paper, a polymer film, or othersuitable polymeric material, for ease of handling and/or to preventcontact between the microwave energy interactive material and the fooditem. The outermost surface of the substrate may define at least aportion of the food-contacting surface of the package (e.g. surface190). Examples of polymer films that may be suitable include, but arenot limited to, polyolefins, polyesters, polyamides, polyimides,polysulfones, polyether ketones, cellophanes, or any combinationthereof. In one particular example, the polymer film comprisespolyethylene terephthalate. The thickness of the film generally may befrom about 35 gauge to about 10 mil. In each of various examples, thethickness of the film may be from about 40 to about 80 gauge, from about45 to about 50 gauge, about 48 gauge, or any other suitable thickness.Other non-conducting substrate materials such as paper and paperlaminates, metal oxides, silicates, cellulosics, or any combinationthereof, also may be used.

The microwave energy interactive material may be applied to thesubstrate in any suitable manner, and in some instances, the microwaveenergy interactive material is printed on, extruded onto, sputteredonto, evaporated on, or laminated to the substrate. The microwave energyinteractive material may be applied to the substrate in any pattern, andusing any technique, to achieve the desired heating effect of the fooditem. For example, the microwave energy interactive material may beprovided as a continuous or discontinuous layer or coating includingcircles, loops, hexagons, islands, squares, rectangles, octagons, and soforth.

Various materials may serve as the base material for the construct 192(and for tray 200 and cover 300). For example, the construct may beformed at least partially from a polymer or polymeric material. Asanother example, all or a portion the construct may be formed from apaper or paperboard material. In one example, the paper has a basisweight of from about 15 to about 60 lbs/ream (lb/3000 sq. ft.), forexample, from about 20 to about 40 lbs/ream. In another example, thepaper has a basis weight of about 25 lbs/ream. In another example, thepaperboard having a basis weight of from about 60 to about 330 lbs/ream,for example, from about 155 to about 265 lbs/ream. In one particularexample, the paperboard has a basis weight of about 175 lbs/ream. Thepaperboard generally may have a thickness of from about 6 to about 30mils, for example, from about 14 to about 24 mils. In one particularexample, the paperboard has a thickness of about 16 mils. Any suitablepaperboard may be used, for example, a solid bleached or solidunbleached sulfate board, such as SUS® board, commercially availablefrom Graphic Packaging International.

The package may be formed according to numerous processes known to thosein the art, including using adhesive bonding, thermal bonding,ultrasonic bonding, mechanical stitching, or any other suitable process.Any of the various components used to form the package may be providedas a sheet of material, a roll of material, or a die cut material in theshape of the package to be formed (e.g., a blank).

It will be understood that with some combinations of elements andmaterials, the microwave energy interactive element may have a grey orsilver color that is visually distinguishable from the substrate or thesupport. However, in some instances, it may be desirable to provide apackage having a uniform color and/or appearance. Such a package may bemore aesthetically pleasing to a consumer, particularly when theconsumer is accustomed to packages or containers having certain visualattributes, for example, a solid color, a particular pattern, and so on.Thus, for example, the present disclosure contemplates using a silver orgrey toned adhesive to join the microwave energy interactive element tothe support, using a silver or grey toned support to mask the presenceof the silver or grey toned microwave energy interactive element, usinga dark toned substrate, for example, a black toned substrate, to concealthe presence of the silver or grey toned microwave energy interactiveelement, overprinting the metallized side of the polymer film with asilver or grey toned ink to obscure the color variation, printing thenon-metallized side of the polymer film with a silver or grey ink orother concealing color in a suitable pattern or as a solid color layerto mask or conceal the presence of the microwave energy interactiveelement, or any other suitable technique or combination of techniques.

Although certain embodiments of this invention have been described witha certain degree of particularity, those skilled in the art could makenumerous alterations without departing from the spirit or scope of thisinvention. Any directional references (e.g., upper, lower, upward,downward, left, right, leftward, rightward, top, bottom, above, below,vertical, horizontal, clockwise, and counterclockwise) are used only foridentification purposes to aid the reader's understanding of variousembodiments, and do not create limitations, particularly as to theposition, orientation, or use of the invention unless specifically setforth in the claims. The relative terms “lower” and “upper” indicateorientations determined in relation to fully erected constructs. Theterms “end” and “side” are not intended to convey any relative sizedifference between end panels and side panels except as specificallyrecited. Joinder references (e.g., joined, attached, coupled, connected,and the like) are to be construed broadly and may include intermediatemembers between a connection of elements and relative movement betweenelements. As such, joinder references do not necessarily imply that twoelements are connected directly and in fixed relation to each other.

It will be understood that in each of the various blanks and packagescontemplated hereby, a “fold line” can be any substantially linear,although not necessarily straight, form of weakening that facilitatesfolding therealong. More specifically, but not for the purpose ofnarrowing the scope of the present invention, a fold line may be a scoreline, such as lines formed with a blunt scoring knife, or the like,which creates a crushed portion in the material along the desired lineof weakness, a cut that extends partially into a material along thedesired line of weakness, and/or a series of cuts that extend partiallyinto and/or completely through the material along the desired line ofweakness, or any combination of these features.

For example, one type of conventional tear line is in the form of aseries of cuts that extend completely through the material, withadjacent cuts being spaced apart slightly so that a nick (e.g., a smallsomewhat bridging-like piece of the material) is defined between theadjacent cuts for typically temporarily connecting the material acrossthe tear line. The nicks are broken during tearing along the tear line.Such a tear line that includes nicks can also be referred to as a cutline, since the nicks typically are a relatively small percentage of thesubject line, and alternatively the nicks can be omitted from such a cutline.

Furthermore, various exemplary blanks and constructs are shown anddescribed herein as having fold lines, tear lines, score lines, cutlines, kiss cut lines, and other lines as extending from a particularfeature to another particular feature, for example from one particularpanel to another, from one particular edge to another, or anycombination thereof. However, it will be understood that such lines neednot necessarily extend between such features in a precise manner.Instead, such lines may generally extend between the various features asneeded to achieve the objective of such line. For instance, where aparticular tear line is shown as extending from a first edge of a panelto another edge of the panel, the tear line need not extend completelyto one or both of such edges. Rather, the tear line need only extend toa location sufficiently proximate to the edge so that the removablestrip, panel, or portion can be manually separated from the blank orconstruct without causing undesirable damage thereto.

It will be readily understood by those persons skilled in the art thatthe present invention is susceptible of broad utility and application.It will also be recognized by those skilled in the art that variouselements discussed with reference to the various embodiments may beinterchanged to create entirely new embodiments coming within the scopeof the present invention. While the present invention is describedherein in detail in relation to specific embodiments, it is to beunderstood that this detailed description is only illustrative andexemplary of the present invention and is made merely for purposes ofproviding a full and enabling disclosure of the present invention and toset forth the best mode of practicing the invention known to theinventors at the time the invention was made. Many adaptations of thepresent invention other than those herein described, as well as manyvariations, modifications, and equivalent arrangements will be apparentfrom or reasonably suggested by the present invention and the abovedetailed description without departing from the substance or scope ofthe present invention. Accordingly, the detailed description set forthherein is not intended nor is to be construed to limit the presentinvention or otherwise to exclude any such other embodiments,adaptations, variations, modifications, and equivalent arrangements ofthe present invention.

1. A microwave heating construct, comprising: a top panel including a line of disruption that defines a removable portion of the top panel; and a bottom panel opposite the top panel, the bottom panel including a plurality of lines of disruption that define a movable portion of the bottom panel and a remaining portion of the bottom panel, wherein the lines of disruption each extend between pairs of adjacent peripheral edges of the bottom panel, wherein the movable portion of the bottom panel and an area of the top panel that circumscribes the removable portion of the top panel each include microwave energy interactive material, and the movable portion of the bottom panel is operative for being moved towards the top panel, wherein the construct is configured so that moving the movable portion of the bottom panel brings the movable portion of the bottom panel into closer proximity with the microwave energy interactive material of the top panel, and the movable portion of the bottom panel is maintained in closer proximity to the microwave energy interactive material of the top panel.
 2. The construct of claim 1, wherein the lines of disruption define chamfered corners of the movable portion of the bottom panel.
 3. The construct of claim 1, further comprising fold lines extending substantially between adjacent pairs of lines of disruption.
 4. The construct of claim 3, wherein the fold lines lie substantially along the peripheral edges of the bottom panel.
 5. The construct of claim 3, wherein the movable portion of the bottom panel is substantially octagonal in shape.
 6. The construct of claim 1, further comprising a plurality of side panels extending between the top panel and the bottom panel, wherein the side panels each include a hingeable portion foldably joined to the movable portion of the bottom panel.
 7. The construct of claim 6, wherein each hingeable portion is foldably joined to the movable portion of the bottom panel along the respective peripheral edge of the bottom panel.
 8. The construct of claim 6, wherein each hingeable portion is defined by a plurality of lines of disruption in the respective side panel.
 9. The construct of claim 8, wherein the plurality of lines of disruption in the respective side panel includes a pair of lines of disruption extending from the respective peripheral edge of the bottom panel towards the top panel, and a fold line extending between the pair of lines of disruption extending from the respective peripheral edge of the bottom panel.
 10. The construct of claim 6, wherein the hingeable portions of the side panels are operative for supporting the movable portion of the bottom panel when the movable portion of the bottom panel is moved towards the top panel.
 11. The construct of claim 1, wherein the microwave energy interactive material of the top panel and the movable portion of the bottom panel is operative for converting at least a portion of impinging microwave energy into thermal energy.
 12. The construct of claim 1, wherein the removable portion of the top panel is substantially circular in shape.
 13. The construct of claim 1, wherein the microwave energy interactive material of the top panel has a generally annular shape.
 14. The construct of claim 1, further comprising a contoured ring for being positioned between the top panel and the bottom panel, wherein the contoured ring comprises microwave energy interactive material.
 15. The construct of claim 14, wherein the contoured ring circumscribes an opening.
 16. The construct of claim 1, further comprising a tray for being positioned on the bottom panel, wherein the tray includes a first portion comprising microwave energy interactive material operative for converting at least a portion of impinging microwave energy into thermal energy, and a second portion that is substantially transparent to microwave energy.
 17. The construct of claim 16, wherein the first portion of the tray further includes a plurality of metal foil segments operative for directing microwave energy towards the center of the tray.
 18. The construct of claim 1, in combination with a food item, wherein the food item has a lower surface and an upper surface that are each desirably at least one of browned and crisped.
 19. The combination of claim 18, wherein the food item is positioned on the movable portion of the bottom panel so that the microwave energy interactive material of the movable portion is proximate to the lower surface of the food item.
 20. A method of using the combination of claim 19, comprising moving the movable portion of the bottom panel towards the top panel, so that the upper surface of the food item is brought into closer proximity to the microwave energy interactive material of the top panel.
 21. The method of claim 20, wherein moving the movable portion of the bottom panel towards the top panel defines venting gaps between the movable portion of the bottom panel and the remaining portion of the bottom panel.
 22. The method of claim 20, wherein the microwave energy interactive material of each the top panel and the moveable portion of the bottom panel is operative for converting microwave energy into heat, and the method further comprises exposing the food item to microwave energy, so that the microwave energy interactive material of the top panel and the moveable portion of the bottom panel convert microwave energy into heat and at least one of browns and crisps the lower surface of the food item, and at least one of browns and crisps the upper surface of the food item.
 23. A microwave heating construct, comprising: a top panel including a removable portion for being separated from the construct to define an opening in the top panel, wherein the top panel includes microwave energy interactive material extending around the removable portion, a bottom panel opposite the top panel, the bottom panel including a movable portion comprising microwave energy interactive material, the movable portion of the bottom panel being defined at least partially by a plurality of lines of disruption extending across the bottom panel between pairs of adjacent peripheral edges of the bottom panel, and a plurality of fold lines extending between adjacent pairs of the plurality of lines of disruption; and a plurality of side panels extending between the top panel and the bottom panel, the side panels each including a hingeable portion foldably joined to the movable portion of the bottom panel, wherein the lines of disruption are for being breached so that the movable portion of the bottom panel can move towards the top panel, wherein moving the movable portion of the bottom panel towards the top panel is for moving a food item seated thereon into closer proximity with the microwave energy interactive material of the top panel.
 24. The construct of claim 23, in combination with the food item, wherein the food item has an upper peripheral surface that is desirably at least one of browned and crisped, an upper central surface that is not desirably browned or crisped, and a lower surface that is desirably at least one of browned and crisped.
 25. The combination of claim 24, wherein the food item is positioned on the movable portion of the bottom panel so that the microwave energy interactive material of the movable portion of the bottom panel underlies the lower surface of the food item.
 26. A method of using the combination of claim 25, comprising breaching the lines of disruption, and moving the movable portion of the bottom panel towards the top panel so that the upper peripheral surface of the food item is proximate to the microwave energy interactive material of the top panel, and the opening overlies the upper central surface of the food item.
 27. The method of claim 26, wherein moving the movable portion of the bottom panel towards the top panel defines a void beneath the movable portion of the bottom panel.
 28. The method of claim 26, wherein the microwave energy interactive material of each the top panel and the moveable portion of the bottom panel is operative for generating heat in response to microwave energy, and the method further comprises exposing the food item positioned on the movable portion of the bottom panel to microwave energy, so that the microwave energy interactive material of each the top panel and the moveable portion of the bottom panel generates heat and the upper peripheral surface of the food item is at least one of browned and crisped, and the lower surface of the food item is at Least one of browned and crisped.
 29. A microwave heating construct, comprising: a top panel including a removable portion for being separated from the construct, wherein the top panel includes microwave energy interactive material extending around the removable portion, a bottom panel opposite the top panel, the bottom panel including a movable portion comprising microwave energy interactive material, the movable portion of the bottom panel being defined at least partially by a plurality of lines of disruption extending across the bottom panel between pairs of adjacent peripheral edges of the bottom panel, and a plurality of fold lines extending between adjacent pairs of the plurality of lines of disruption, wherein the bottom panel is substantially rectangular in shape, so that the movable portion of the bottom panel is substantially octagonal in shape, and so that the lines of disruption define a remaining portion of the construct; and a plurality of side panels extending between the top panel and the bottom panel, the side panels each including a hingeable portion foldably joined to the movable portion of the bottom panel, the hingeable portion of each side panel being operative for moving with the movable portion of the bottom panel, wherein the movable portion of the bottom panel is for moving a food item seated on the movable portion of the bottom panel towards the microwave energy interactive material of the top panel, and defining a void beneath the movable portion of the bottom panel, so that the remaining portion of the bottom panel supports the construct.
 30. The construct of claim 29, in combination with a food item, wherein the food item has an upper surface that is desirably at least one of browned and crisped, and a lower surface that is desirably at least one of browned and crisped.
 31. The combination of claim 30, wherein the food item is positioned on the movable portion of the bottom panel so that the microwave energy interactive material of the movable portion of the bottom panel underlies the lower surface of the food item.
 32. A method of using the combination of claim 31, comprising moving the food item seated on the movable portion of the bottom panel towards the microwave energy interactive material of the top panel so that the microwave energy interactive material of the top panel overlies the upper surface of the food item, and defining the void beneath the movable portion of the bottom panel, so that the remaining portion of the bottom panel serves to support the construct.
 33. The method of claim 32, wherein moving the food item seated on the movable portion of the bottom panel towards the microwave energy interactive material of the top panel defines venting gaps adjacent to the remaining portion of the bottom panel.
 34. The method of claim 32, wherein the microwave energy interactive material of each the top panel and the moveable portion of the bottom panel is operative for heating in response to microwave energy, and the method further comprises exposing the food item to microwave energy, so that the microwave energy interactive material of each the top panel and the moveable portion of the bottom panel heats and the upper surface of the food item is at least one of browned and crisped, and the lower surface of the food item is at least one of browned and crisped. 